Tubular handling apparatus

ABSTRACT

In one embodiment, a tubular handling assembly for use with a top drive includes a mandrel coupled to the top drive; a gripping assembly for gripping and releasing a tubular, the gripping assembly coupled to and rotating with the mandrel; and an actuation assembly for actuating the gripping assembly, wherein the gripping assembly is rotatable relative to the actuation assembly.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the invention generally relate to an apparatus forhandling tubulars using top drive systems. More particularly, theinvention relates to a tubular handling apparatus for engaging a tubularand rotating at the same time.

2. Description of the Related Art

In the drilling and completion of wells, top drive systems are used torotate a drill string to form a borehole. Top drive systems may also beused in a drilling with casing operation to rotate the casing. Topdrives require a gripping element to facilitate the gripping oftubulars, whether the tubular is a drill string or a casing, andtherefore, there is a need for an apparatus for adapting the top driveand engaging and rotating a tubular.

SUMMARY OF THE INVENTION

In one embodiment, a tubular handling assembly for use with a top driveincludes a mandrel coupled to the top drive; a gripping assembly forgripping and releasing a tubular, the gripping assembly coupled to androtating with the mandrel; and an actuation assembly for actuating thegripping assembly, wherein the gripping assembly is rotatable relativeto the actuation assembly.

In another embodiment, a tubular handling assembly for use with a topdrive includes a mandrel coupled to the top drive; a gripping assemblyfor gripping and releasing a tubular, the gripping assembly coupled toand rotating with the mandrel; a link assembly rotationally coupled tothe mandrel; an actuator coupling rotationally coupled to the grippingassembly; and a plurality of actuators connected to the link assemblyand the actuator coupling, wherein the plurality of actuators areconfigured to actuate the gripping assembly and the gripping assembly isrotatable relative to the plurality of actuators.

In another embodiment, a tubular handling assembly for use with a topdrive includes a mandrel coupled to the top drive; a gripping assemblyfor gripping and releasing a tubular, the gripping assembly coupled toand rotating with the mandrel; a link assembly coupled to the mandrelusing a first bearing assembly; and an actuation cylinder coupled to thelink assembly and to a ring assembly, wherein the actuation cylinderaxially moves the ring assembly relative to the link assembly, andwherein the gripping assembly is coupled to the ring assembly using asecond bearing assembly.

In another embodiment, a method of handling a tubular using a top driveincludes coupling a mandrel to the top drive; rotationally coupling agripping assembly to the mandrel, wherein the gripping assembly isconfigured to grip a tubular; coupling an actuation assembly to thegripping assembly, wherein the actuation assembly is configured toactuate the gripping assembly; gripping the tubular using the grippingassembly; and rotating the gripping assembly and the tubular relative tothe actuation assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the inventioncan be understood in detail, a more particular description of theinvention, briefly summarized above, may be had by reference toembodiments, some of which are illustrated in the appended drawings. Itis to be noted, however, that the appended drawings illustrate onlytypical embodiments of this invention and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 is a perspective view of an embodiment of a tubular handlingapparatus adapted to engage an external surface of a tubular;

FIG. 2 is a cross-sectional view of the tubular handling apparatus shownin FIG. 1;

FIG. 3 is a perspective view of an embodiment of a tubular handlingapparatus adapted to engage an internal surface of a tubular; and

FIG. 4 is a partial cross-sectional view of the tubular handlingapparatus shown in FIG. 3.

DETAILED DESCRIPTION

Embodiments of the invention provide a tubular handling apparatus foruse with a top drive to engage and rotate a tubular such as a casing.FIG. 1 is a perspective view of an embodiment of a tubular handlingapparatus adapted to engage an external surface of the tubular. Theapparatus shown in FIG. 1 will be referred to herein as an externalgripping tool 100. The external gripping tool 100 generally includes amandrel 110 for connecting to a top drive, a link assembly 120, anactuator coupling such as a leveling ring assembly 160, and a carrier180 for gripping a tubular, which is also connected to the mandrel 110.The link assembly 120 and the leveling ring assembly 160 may assist withaxial loads and support actuation members such as hydraulic or pneumaticcylinders while the carrier 180 includes gripping elements 182 forgripping a tubular. The mandrel 110 is used to rotate the tubular viathe carrier 180.

FIG. 2 is a cross-sectional view of the tubular handling apparatus shownin FIG. 1. The link assembly 120 includes a link support housing 122 andlinks 124. The link support housing 122 includes a central opening 126for receiving the mandrel 110, and the link support housing 122 isconnected to the mandrel 110 via a coupling ring 128. The coupling ring128 is attached to the mandrel 110 and rotates with the mandrel 110. Inone embodiment, the coupling ring 128 could be a nut which threadedlyattaches to an exterior surface of the mandrel 110.

A first bearing assembly 130 and a second bearing assembly 132 arecoupled to the coupling ring 128 at an inner portion of the first andsecond bearing assemblies 130, 132, and the first and second bearingassemblies 130, 132 are coupled to the link support housing 122 at anexterior portion of the first and second bearing assemblies 130, 132.The bearing assemblies 130, 132, in one embodiment, include an innerring and an outer ring with balls disposed between the two rings. Insuch configuration, the coupling ring 128 is connected to the innerportion of the inner ring of the bearing assemblies 130, 132, and thelink support housing 122 is connected to the exterior portion of theouter ring of the bearing assemblies 130, 132.

As shown in FIG. 2, the first bearing assembly 130 is positioned at anupper portion of the link support housing 122 and an upper portion ofthe coupling ring 128. In one embodiment, the coupling ring 128 includesan upper shoulder or groove for accepting the first bearing assembly130. An optional retainer 134 may be used to retain the bearingassembly. The second bearing assembly 132 is positioned at a lowerportion of the link support housing 122 and a lower portion of thecoupling ring 128. In one embodiment, the coupling ring 128 includes alower shoulder or groove for accepting the second bearing assembly 132.Because the link support housing 122 is connected to the mandrel 110 viathe coupling ring 128 and first and second bearing assemblies 130, 132,the link support assembly 120 does not rotate with the mandrel 110.However, axial loads experienced by the links 124 may be transferred tothe mandrel 110 via the bearing assemblies 130, 132. Further, becausethe bearing assemblies 130, 132 are positioned at a top and bottomportion of the link support housing 122, the first and second bearingassemblies 130, 132 balance the loads acting on the assemblies 130, 132.

In one embodiment, a torque reaction bracket may be attached to the linksupport assembly 120 to prevent the link support housing 122 fromrotating in relation to the mandrel 110 and the coupling ring 128. Oneend of the torque reaction bracket may be coupled to the link supportassembly 120 and the other end of the torque reaction bracket may becoupled to a rotationally fixed location, such as a rail on a drillingderrick or part of the top drive. In another embodiment, the torquereaction bracket may be attached to the leveling ring member 162 of theleveling ring assembly 160 to prevent rotation of the leveling ringmember 162. One end of the torque reaction bracket may be coupled to theleveling ring member 162 and the other end of the torque reactionbracket may be coupled to a rotationally fixed location, such as a railon a drilling derrick or part of the top drive.

Actuation cylinders 136 are coupled to the link support assembly 120 andto the leveling ring assembly 160. In one embodiment, the actuationcylinders 136 are coupled to the link support housing 122 of the linksupport assembly 120 and a leveling ring member 162 of the leveling ringassembly 160. The actuation cylinders 136 allow the leveling ringassembly 160 to be axially moved relative to the link support assembly120. In addition, torque support bars 138 (shown in FIG. 1), which inone embodiment are telescoping torque support bars, may optionally beconnected to the link support assembly 120 and the leveling ringassembly 160 in order to provide structural support to the tubularhandling apparatus 100. The torque support bars 138 may also keep thelink support assembly 120 aligned with the leveling ring assembly 160.

The leveling ring assembly 160 includes a leveling ring member 162 thatis connected to a slip link coupling 164. The leveling ring member 162and slip link coupling 164 are connected by a first and second levelingring bearing assembly 170, 172. As shown, the leveling ring 160 forms anouter ring and the slip link coupling 164 forms an inner ring. The sliplink coupling 164 is coupled a slip link assembly 176, which is coupledto the carrier 180. Because the carrier 180 is connected to the mandrel110, which rotates, the slip link assembly 176 and the slip linkcoupling 164 also rotate. However, the leveling ring member 162, whichdoes not rotate, is connected to the slip link coupling 164 by the firstand second leveling ring bearing assemblies 170, 172. Further, theleveling ring member 162 may be prevented from rotating by the actuationcylinders 136 and the optional torque support bars 138.

The slip link assembly 176 may include one or more links 178 that areconnected to gripping elements 182, which are disposed in a window ofthe carrier 180. As the slip link assembly 176 axially moves with theleveling ring assembly 160, the links 178 move the gripping elements 182within the carrier 180. The leveling ring assembly 160 helps ensure thatthe gripping elements 182 move in unison. The actuation cylinders 136can be retracted to move the leveling ring assembly 160 upwards relativeto the link assembly 120. In turn, the links 178 of the slip linkassembly 176 move upwards with the leveling ring assembly 160, therebylifting the gripping elements 182 upward to the non-gripping position.In one embodiment, the links keep the gripping elements 182 in theproper position relative to the window. When the actuation cylinders 136are in an extended position, the leveling ring assembly 160 is furthestdown axially, and the links 178 position the gripping elements 182 in agripping position. Once the tubular is clamped, the top drive may rotatethe mandrel 110 and the clamped tubular. To unclamp the tubular, theactuation cylinders 136 may be actuated to move back to their retractedposition, which in turn will move the leveling ring assembly 160 andslip link assembly 176 up relative to the carrier 180, thereby causingthe gripping elements 182 to release the tubular. Optionally, theinternal gripping tool 200 may be equipped with a fill-up tool 290.

In one embodiment, a bracket 190 (shown in FIG. 1) is connected to twoof the links 124. The bracket 190 keeps the links 124 aligned duringoperation. For example, during pick up of a tubular, the bracket 190prevents the links 124 from twisting relative to each other.

FIG. 3 is a perspective view of an embodiment of a tubular handlingapparatus adapted to engage an internal surface of the tubular, and willbe referred to herein as an internal gripping tool 200. The internalgripping tool 200 generally includes a mandrel 210 for connecting to atop drive and rotating the tubular, a link assembly 220 for supportingbails, a hydraulic actuator 218, which is in part supported by the linkassembly 220, and gripping elements 280 for gripping a tubular from theinternal surface of the tubular when actuated by the hydraulic actuator218. Optionally, the internal gripping tool 200 may be equipped with afill-up tool 290.

FIG. 4 is a cross-sectional view of a top portion of the internalgripping tool 200 shown in FIG. 3. The link assembly 220 includes a linksupport housing 222 that includes a central opening 226 for receivingthe mandrel 210, and the link support housing 222 is connected to themandrel 210 via a coupling ring 228. The coupling ring 228 is attachedto the mandrel 210 and rotates with the mandrel 110. In one embodiment,the coupling ring 228 could be a nut which threadedly attaches to anexterior surface of the mandrel 210.

A first bearing assembly 230 and a second bearing assembly 232 arecoupled to the coupling ring 228 at an inner portion of the first andsecond bearing assemblies 230, 232, and the first and second bearingassemblies 230, 232 are coupled to the link support housing 222 at anexterior portion of the first and second bearing assemblies 230, 232.The bearing assemblies 230, 232, in one embodiment, include an innerring and an outer ring with balls disposed between the two rings. Insuch configuration, the coupling ring 228 is coupled to the innerportion of the inner ring of the bearing assemblies 230, 232, and thelink support housing 222 is coupled to the exterior portion of the outerring of the bearing assemblies 230, 232. As shown in FIG. 4, the firstbearing assembly 230 is positioned at an upper portion of the linkassembly 220 and at an upper portion of the coupling ring 228. In oneembodiment, the coupling ring 228 includes an upper shoulder or groovefor accepting the first bearing assembly 230. The second bearingassembly 232 is positioned at a lower portion of the link assembly 220and a lower portion of the coupling ring 228. In one embodiment, thecoupling ring 228 includes a lower shoulder or groove for accepting thesecond bearing assembly 232. Because the link support housing 222 isconnected to the mandrel 210 via the coupling ring 228 and first andsecond bearing assemblies 230, 232, the link support assembly 220 doesnot rotate with the mandrel 210. A torque reaction bracket may beprovided to attach the non-rotating components to a fixture, such as arail on a drilling derrick.

The hydraulic actuator 218 includes one or more actuation cylinders 236,which are coupled to the link support assembly 220 at an upper end, andcoupled to an engagement plate 240 at a lower end. Bolts 224 or anyother suitable fastening mechanism known to one skilled in the art, suchas a pin connection, may be used to fasten the actuation cylinders 236to the link support assembly 220 and the engagement plate 240.Optionally, torque support bars 238 shown in FIG. 3, which in oneembodiment are telescoping torque support bars, may optionally beconnected to the link assembly 220 and the engagement plate 240 in orderto provide structural support to the tubular handling apparatus 200.

An actuator coupling 242 is positioned between the actuation cylinders236 and the engagement plate 240, and extends from the actuationcylinders 236 to an actuator pipe 250. The actuator pipe 250 isconnected to the gripping elements 280. The actuator coupling 242 isconnected to the actuator pipe 250 by a third bearing assembly 244. Asshown, the actuator coupling 242 is disposed around the actuator pipe250. Because the actuator pipe 250 is connected to the gripping elements280, which in turn are coupled to the mandrel 210, the actuator pipe 250rotates with the mandrel 210. However, because the actuator pipe 250 isconnected to the actuator coupling 242 via the third bearing assembly244, the actuator coupling 242 remains stationary along with theactuation cylinders 236 and the engagement plate 240.

Actuation of the actuation cylinders 236 urges axial movement of theactuator coupling 242 and actuator pipe 250. When the actuationcylinders 236 are actuated to expand, a portion of the cylinders movedownwards relative to the link support assembly 220. The grippingelements 280 are moved axially downwards relative to the mandrel 110 andresult in the internal gripping tool 200 gripping the internal portionof the tubular. When the actuation cylinders 236 are actuated tocontract, a portion of the cylinders move upwards relative to the linksupport assembly 220. The gripping elements 280 are moved axiallyupwards relative to the mandrel 110 and result in the internal grippingtool 200 releasing the internal portion of the tubular.

In use, the internal gripping tool 200 is positioned within an innerdiameter of a tubular. The upper end of the tubular may engage or isproximate a bottom portion of the engagement plate 240. The grippingelements 280 may be actuated by the non-rotating actuation cylinders 236to grip an internal surface of the tubular. As discussed above, theactuation cylinders 236 are isolated from rotation by first, second, andthird bearing assemblies 230, 232, 244 that provide a connection betweenthe link support assembly 220 to the mandrel 210 and the connectionbetween the actuator coupling 242 and engagement plate 240 to themandrel 210. The engagement plate 240 may act to limit the verticalposition of the tubular relative to the internal gripping tool 200.After the internal gripping tool 200 grips the internal surface of thetubular, the mandrel 210 may be rotated by the top drive to thread onejoint of the gripped tubular to another tubular. As the mandrel 210 andthe gripping elements 280 rotate, the actuation cylinders 236 thatposition the gripping elements 280 relative to the tubular do not rotateand are able to maintain the appropriate tension on the grippingelements 280. After the tubulars are made up or threaded together, thetop drive may stop rotation of the mandrel 210, and the grippingelements 280 may be actuated by the actuation cylinders 236 to releasethe internal surface of the tubular.

In one embodiment, a tubular handling assembly for use with a top driveincludes a mandrel coupled to the top drive; a gripping assembly forgripping and releasing a tubular, the gripping assembly coupled to androtating with the mandrel; a link assembly rotationally coupled to themandrel; an actuator coupling rotationally coupled to the grippingassembly; and a plurality of actuators connected to the link assemblyand the actuator coupling, wherein the plurality of actuators areconfigured to actuate the gripping assembly and the gripping assembly isrotatable relative to the plurality of actuators.

In one or more of the embodiments described herein, a slip link couplingis disposed around the actuator coupling.

In one or more of the embodiments described herein, the plurality ofactuators are connected to the actuator coupling and the grippingassembly is coupled to the slip link coupling.

In one or more of the embodiments described herein, the grippingassembly is configured to grip an exterior surface of a tubular.

In one or more of the embodiments described herein, the actuatorcoupling is disposed around an actuator pipe.

In one or more of the embodiments described herein, the grippingassembly is configured to grip an interior surface of a tubular.

In one or more of the embodiments described herein, the plurality ofactuators are configured to axially move the actuator coupling.

In one or more of the embodiments described herein, the actuatorcoupling comprises a leveling ring.

In one or more of the embodiments described herein, one or more bearingassemblies couples the actuator coupling to the gripping assembly.

In one or more of the embodiments described herein, the plurality ofactuators comprise a piston and cylinder assembly.

In one or more of the embodiments described herein, the actuatorcoupling is axially moved relative to the link assembly.

In one or more of the embodiments described herein, one or more bearingassemblies rotationally couples the link assembly to the mandrel.

In another embodiment, a tubular handling assembly for use with a topdrive includes a mandrel coupled to the top drive; a gripping assemblyfor gripping and releasing a tubular, the gripping assembly coupled toand rotating with the mandrel; a link assembly coupled to the mandrelusing a first bearing assembly; and a plurality of actuation cylinderscoupled to the link assembly and to a ring assembly, wherein theplurality of actuation cylinders axially move the ring assembly relativeto the link assembly, and wherein the gripping assembly is coupled tothe ring assembly using a second bearing assembly.

In one or more of the embodiments described herein, a torque reactionbracket is coupled to the link assembly and to a rotationally fixedlocation to prevent the link assembly from rotating.

In one or more of the embodiments described herein, a torque support baris coupled to the link assembly and the ring assembly to providestructural support.

In one or more of the embodiments described herein, the grippingassembly includes a plurality of gripping elements coupled to a housing.

In one or more of the embodiments described herein, the grippingelements engage an external surface of the tubular.

In one or more of the embodiments described herein, the grippingassembly includes a plurality of gripping elements coupled to anactuator pipe.

In one or more of the embodiments described herein, the grippingelements engage an internal surface of the tubular.

In another embodiment, a method of handling a tubular using a top driveincludes coupling a mandrel to the top drive; rotationally coupling agripping assembly to the mandrel, wherein the gripping assembly isconfigured to grip a tubular; coupling a link assembly to the mandrel;disposing a plurality of actuation assemblies between the link assemblyand a slip coupling, wherein the plurality of actuation assemblies areconfigured to actuate the gripping assembly; actuating the grippingassembly to grip the tubular by moving the slip coupling axiallyrelative to the link assembly; and rotating the gripping assembly andthe tubular relative to the plurality of actuation assemblies.

While the foregoing is directed to embodiments of the invention, otherand further embodiments of the invention may be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

1. A tubular handling assembly for use with a top drive, comprising: amandrel coupled to the top drive; a gripping assembly for gripping andreleasing a tubular, the gripping assembly coupled to and rotating withthe mandrel; a link assembly rotationally coupled to the mandrel; anactuator coupling rotationally coupled to the gripping assembly; and aplurality of actuators connected to the link assembly and the actuatorcoupling, wherein the plurality of actuators are configured to actuatethe gripping assembly and the gripping assembly is rotatable relative tothe plurality of actuators.
 2. The assembly of claim 1, furthercomprising a slip link coupling disposed around the actuator coupling.3. The assembly of claim 2, wherein the plurality of actuators areconnected to the actuator coupling and the gripping assembly is coupledto the slip link coupling.
 4. The assembly of claim 3, wherein thegripping assembly is configured to grip an exterior surface of atubular.
 5. The assembly of claim 1, wherein the actuator coupling isdisposed around an actuator pipe.
 6. The assembly of claim 5, whereinthe gripping assembly is configured to grip an interior surface of atubular.
 7. The assembly of claim 1, wherein the plurality of actuatorsare configured to axially move the actuator coupling.
 8. The assembly ofclaim 1, wherein the actuator coupling comprises a leveling ring.
 9. Theassembly of claim 1, further comprising one or more bearing assembliesfor coupling the actuator coupling to the gripping assembly.
 10. Theassembly of claim 1, wherein the plurality of actuators comprise apiston and cylinder assembly.
 11. The assembly of claim 1, wherein theactuator coupling is axially moved relative to the link assembly. 12.The assembly of claim 1, further comprising one or more bearingassemblies for rotationally coupling the link assembly to the mandrel.13. A tubular handling assembly for use with a top drive, comprising: amandrel coupled to the top drive; a gripping assembly for gripping andreleasing a tubular, the gripping assembly coupled to and rotating withthe mandrel; a link assembly coupled to the mandrel using a firstbearing assembly; and a plurality of actuation cylinders coupled to thelink assembly and to a ring assembly, wherein the plurality of actuationcylinders axially move the ring assembly relative to the link assembly,and wherein the gripping assembly is coupled to the ring assembly usinga second bearing assembly.
 14. The assembly of claim 13, furthercomprising a torque reaction bracket that is coupled to the linkassembly and to a rotationally fixed location to prevent the linkassembly from rotating.
 15. The assembly of claim 13, further comprisinga torque support bar that is coupled to the link assembly and the ringassembly to provide structural support.
 16. The assembly of claim 13,wherein the gripping assembly includes a plurality of gripping elementscoupled to a housing.
 17. The assembly of claim 16, the grippingelements engage an external surface of the tubular.
 18. The assembly ofclaim 13, wherein the gripping assembly includes a plurality of grippingelements coupled to an actuator pipe.
 19. The assembly of claim 18,wherein the gripping elements engage an internal surface of the tubular.20. A method of handling a tubular using a top drive, comprising:coupling a mandrel to the top drive; rotationally coupling a grippingassembly to the mandrel, wherein the gripping assembly is configured togrip a tubular; coupling a link assembly to the mandrel; disposing aplurality of actuation assemblies between the link assembly and a slipcoupling, wherein the plurality of actuation assemblies are configuredto actuate the gripping assembly; actuating the gripping assembly togrip the tubular by moving the slip coupling axially relative to thelink assembly; and rotating the gripping assembly and the tubularrelative to the plurality of actuation assemblies.